Proportional solenoid valve

ABSTRACT

A valve including a valve assembly and a solenoid assembly. The solenoid assembly is coupled to the valve assembly to actuate the valve assembly. The solenoid assembly includes a movable armature engaged with a poppet of the valve assembly. A plate spring having a spring force is positioned between the valve assembly and the solenoid assembly that is configured to bias the valve member of the poppet into engagement with a valve seat. Based on the spring force of the plate spring and the voltage or current that is applied to the solenoid coil, the solenoid assembly is configured to control a distance that the valve member moves relative to the valve seat to proportionally control an amount of flow that is permitted through the valve assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/130,796, filed on Dec. 22, 2020. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to a proportional solenoid valve.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Valves with proportional control provide increased control over theamount of fluid that can pass through the valve. This can beparticularly important in applications where a specific amount of gassuch as oxygen is being provided to a patient before, during, or after amedical procedure. In this regard, if the correct amount of the gas isnot provided to the patient, the patient may experience negativeeffects. Other applications that may require proportional controlincluding providing a correct amount of carbonation to a beverage,providing fluid pressure control to a mobility assist unit, andapplications that require fluid dosing.

Previous proportional control valves used components to actuate thevalve that were expensive such as stepper motors. In addition, previousvalves were susceptible to fluctuations in pressure that affected theamount of fluid that may be permitted to pass through the valve. Thereis a need, therefore, for a valve that is less expensive, has increasedcontrol over the amount of fluid that can pass through the valve, andthat includes a design that is not susceptible to fluctuations inpressure that can affect the amount of flow through the valve.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

According to a first aspect of the present disclosure, there is provideda valve that includes a block having a cavity positioned between a fluidinlet and a fluid outlet. A valve assembly is positioned within thecavity that selectively permits communication between the fluid inletand the fluid outlet. The valve assembly includes a hollow valveretainer having a first port that communicates with the fluid inlet, asecond port that communicates with the fluid outlet, and a valve seatbetween the first port and the second port. The hollow valve retainerhouses a movable poppet including a valve member that is configured isengage and disengage with the valve seat to permit fluid to travel fromthe fluid inlet through the first port to the second port, and then tothe fluid outlet. A solenoid assembly is coupled to the valve assemblythat is configured to actuate the valve assembly to permit thecommunication between the fluid inlet and the fluid outlet. The solenoidassembly includes a movable armature engaged with the poppet, a firstbushing that surrounds the armature, a plate spring positioned betweenthe armature and the first bushing, and a solenoid coil that isconfigured to move the armature and the poppet to permit thecommunication between the fluid inlet and the fluid outlet. The platespring is configured to bias the valve member of the poppet intoengagement with the valve seat of the valve retainer. The plate springhas a predictable spring force. The solenoid coil is configured to movethe armature and the poppet based a voltage or current that is appliedto the solenoid coil, and based on the spring force of the plate springand the voltage or current that is applied to the solenoid coil, thesolenoid assembly is configured to control a distance that the valvemember moves relative to the valve seat of the valve retainer toproportionally control an amount of flow that is permitted through thevalve assembly.

In the valve according to the first aspect, the valve assembly mayfurther include an adjustable valve seat that is coupled to the valveretainer, is positioned about the poppet, and includes a terminal endthat is engageable with the valve member when the valve member is movedaway from the valve seat of the valve retainer.

In the valve according to the first aspect, the adjustable valve seat isthreadingly coupled to the valve retainer, and a position of theadjustable valve seat is variable by adjusting an amount of threadingengagement between the adjustable valve seat and the valve retainer.

In the valve according to the first aspect, the solenoid assembly mayinclude a pole piece having a position in the solenoid assembly that isadjustable, and in combination with adjusting the position of theadjustable valve seat, the valve assembly is configured to providedifferent flow capabilities between the fluid inlet and the fluidoutlet.

In the valve according to the first aspect, the solenoid assembly mayfurther include a second bushing that houses a pole piece that islocated proximate the armature, and that is configured to be magnetizedby the coil to attract the armature to open the valve assembly.

In the valve according to the first aspect, the plate spring includes anannular body having a central aperture configured for receipt of thearmature, and a plurality of secondary apertures that are locatedradially outward from the central aperture.

In the valve according to the first aspect, the first bushing mayinclude a stepped recess that is configured for receipt of the platespring, wherein the stepped recess includes a first annular surface anda second annular surface located radially inward from the first annularsurface, and the plate spring is mounted to the first annular surface.

In the valve according to the first aspect, the valve may furtherinclude an adapter bushing that is configured to connect the solenoidassembly to the valve assembly.

In the valve according to the first aspect, the valve assembly mayfurther include a first diaphragm located proximate a first end of thevalve retainer, and a second diaphragm located proximate an opposingsecond end of the valve retainer and the armature, wherein the first andsecond diaphragms are configured to balance fluid pressures exerted atthe fluid inlet and the fluid outlet to prevent fluctuations in thefluid pressures exerted at the fluid inlet and fluid outlet fromaffecting performance of the valve assembly

In the valve according to the first aspect, each of the first and seconddiaphragms may be formed of an annular plate that includes an annularbead that surrounds a central aperture of the annular pate, wherein thebead is defined by a first annular inclined surface and second annularinclined surface.

In the valve according to the first aspect, the valve assembly mayfurther include a first end cap mated to a first end of the valveretainer and a second end cap mated to an opposite second end of thevalve retainer, wherein the first diaphragm is sandwiched between thefirst end cap and the first end of the valve retainer, and the seconddiaphragm is sandwiched between the second end cap and the second end ofthe valve retainer.

In the valve according to the first aspect, the valve assembly mayinclude a plurality of seal members between the poppet and the valveretainer, the plurality of seal members configured to balance fluidpressures exerted at the fluid inlet and the fluid outlet to preventfluctuations in the fluid pressures exerted at the fluid inlet and fluidoutlet from affecting performance of the valve assembly.

According to a second aspect of the present disclosure, there isprovided a valve that includes a block having a cavity positionedbetween a fluid inlet and a fluid outlet. A valve assembly is positionedwithin the cavity that selectively permits communication between thefluid inlet and the fluid outlet. The valve assembly includes a hollowvalve retainer having a first end and an opposing second end, a firstport that communicates with the fluid inlet, a second port thatcommunicates with the fluid outlet, and a valve seat between the firstport and the second port; a movable poppet located within the valveretainer, the poppet including a valve member that is configured isengage and disengage with the valve seat to permit fluid to travel fromthe fluid inlet through the first port to the second port, and then tothe fluid outlet; an adjustable valve seat that is coupled to the valveretainer, is positioned about the poppet, and includes a terminal endthat is engageable with the valve member when the valve member is movedaway from the valve seat of the valve retainer; a first diaphragmlocated proximate a first end of the valve retainer; a second diaphragmlocated proximate the opposing second end of the valve retainer; a firstend cap mated to the first end of the valve retainer; and a second endcap mated to the opposing second end of the valve retainer, wherein thefirst diaphragm is sandwiched between the first end cap and the firstend of the valve retainer, and the second diaphragm is sandwichedbetween the second end cap and the second end of the valve retainer. Asolenoid assembly is coupled to the valve assembly that is configured toactuate the valve assembly to permit the communication between the fluidinlet and the fluid outlet. The solenoid assembly includes a movablearmature engaged with the poppet, a first bushing that surrounds thearmature, a plate spring positioned between the armature and the firstbushing, and a solenoid coil that is configured to move the armature andthe poppet to permit the communication between the fluid inlet and thefluid outlet. The plate spring is configured to bias the valve member ofthe poppet into engagement with the valve seat of the valve retainer,the plate spring having a spring force, the solenoid coil is configuredto move the armature and the poppet based a voltage or current that isapplied to the solenoid coil, and based on the spring force of the platespring and the voltage or current that is applied to the solenoid coil,the solenoid assembly is configured to control a distance that the valvemember moves relative to the valve seat of the valve retainer toproportionally control an amount of flow that is permitted through thevalve assembly.

In the valve according to the second aspect, the adjustable valve seatmay be threadingly coupled to the valve retainer such that a position ofthe adjustable valve seat is variable by adjusting an amount ofthreading engagement between the adjustable valve seat and the valveretainer.

In the valve according to the second aspect, the solenoid assembly mayinclude a pole piece having a position in the solenoid assembly that isadjustable, and in combination with adjusting the position of theadjustable valve seat, the valve assembly is configured to providedifferent flow capabilities between the fluid inlet and the fluidoutlet.

In the valve according to the second aspect, the solenoid assembly mayfurther include a second bushing that houses a pole piece that islocated proximate the armature, and that is configured to be magnetizedby the coil to attract the armature to open the valve assembly.

In the valve according to the second aspect, the plate spring includesan annular body having a central aperture configured for receipt of thearmature, and a plurality of secondary apertures that are locatedradially outward from the central aperture.

In the valve according to the second aspect, the first bushing includesa stepped recess that is configured for receipt of the plate spring,wherein the stepped recess includes a first annular surface and a secondannular surface located radially inward from the first annular surface,and the plate spring is mounted to the first annular surface.

In the valve according to the second aspect, the valve may include anadapter bushing that is configured to connect the solenoid assembly tothe valve assembly.

In the valve according to the second aspect, each of the first andsecond diaphragms are formed of an annular plate that includes anannular bead that surrounds a central aperture of the annular pate,wherein the bead is defined by a first annular inclined surface andsecond annular inclined surface.

In the valve according to the second aspect, the first and seconddiaphragms are configured to balance fluid pressures exerted at thefluid inlet and the fluid outlet to prevent fluctuations in the fluidpressures exerted at the fluid inlet and fluid outlet from affectingperformance of the valve assembly.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

FIGS. 1 to 3 are perspective views of a valve according to a firstaspect of the present disclosure;

FIG. 4 is an exploded perspective view of the valve illustrated in FIGS.1 to 3 ;

FIG. 5 is a cross-sectional view along the line 5-5 in FIG. 3 ;

FIG. 6 is a cross-sectional view along the line 6-6 in FIG. 3 ;

FIGS. 7 to 9 are perspective views of a valve according to a secondaspect of the present disclosure;

FIG. 10 is an exploded perspective view of the valve illustrated inFIGS. 7 to 9 ;

FIG. 11 is a cross-sectional view along the line 11-11 in FIG. 9 ; and

FIG. 12 is a cross-sectional view along the line 12-12 in FIG. 9 .

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings.

Firstly, it should be understood that the example embodiments areprovided so that this disclosure will be thorough, and will fully conveythe scope to those who are skilled in the art. Numerous specific detailsare set forth such as examples of specific components, devices, andmethods, to provide a thorough understanding of embodiments of thepresent disclosure. It will be apparent to those skilled in the art thatspecific details need not be employed, that example embodiments may beembodied in many different forms and that neither should be construed tolimit the scope of the disclosure. In some example embodiments,well-known processes, well-known device structures, and well-knowntechnologies are not described in detail.

Further, when an element or layer is referred to as being “on,” “engagedto,” “connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

In addition, although the terms first, second, third, etc. may be usedherein to describe various elements, components, regions, layers and/orsections, these elements, components, regions, layers and/or sectionsshould not be limited by these terms. These terms may be only used todistinguish one element, component, region, layer or section fromanother region, layer or section. Terms such as “first,” “second,” andother numerical terms when used herein do not imply a sequence or orderunless clearly indicated by the context. Thus, a first element,component, region, layer or section discussed below could be termed asecond element, component, region, layer or section without departingfrom the teachings of the example embodiments.

Moreover, spatially relative terms, such as “inner,” “outer,” “beneath,”“below,” “lower,” “above,” “upper,” and the like, may be used herein forease of description to describe one element or feature's relationship toanother element(s) or feature(s) as illustrated in the figures.Spatially relative terms may be intended to encompass differentorientations of the device in use or operation in addition to theorientation depicted in the figures. For example, if the device in thefigures is turned over, elements described as “below” or “beneath” otherelements or features would then be oriented “above” the other elementsor features. Thus, the example term “below” can encompass both anorientation of above and below. The device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly.

FIGS. 1-6 illustrate a proportional solenoid valve apparatus 10according to a first aspect of the present disclosure. Valve apparatus10 is configured to proportionally control a flow of fluid, includingliquids and gases. Valve apparatus 10 includes a housing or portedcavity block 12. Cavity block 12 is generally a cubic or rectangularcubic structure having a plurality of sides 14 a, 14 b, 14 c, 14 d, 14e, and 14 f. Side 14 a includes a threaded inlet port 16 and an oppositeside 14 b includes a threaded outlet port 18. As best shown in FIG. 5 ,inlet port 16 is not axially aligned with outlet port 18. Side 14 fincludes an opening 20 that leads to an interior cavity 22 formed withincavity block 12. Cavity 22 communicates with each of inlet port 16 andoutlet port 18. Side 14 e includes an elongated recess 23 having acentral vent port 25. Recess 23 may be used to mount cavity block 12 toa system that uses valve apparatus 10.

While inlet port 16 is illustrated as being formed on side 14 a that isopposite to the side 14 b that includes outlet port 18, it should beunderstood that the inlet port 16 and outlet port 18 can be formed onadjacent sides of the cavity block 12, if desired. Moreover, while inletport 16 and outlet port 18 are described as being threaded, whichpermits an adapter or some other type of device that provides and/orreceives a flow of fluid to be attached to cavity block 12, it should beunderstood that other attachment methods are contemplated. It shouldalso be understood that the inlet port 16 and the outlet port 18 mayhave their functions reversed (i.e., inlet port 16 may function as anoutlet port, and outlet port 18 may function as an inlet port). Ineither configuration, the valve apparatus 10 will function in the samemanner. Cavity block 12 is preferably formed of a rigid material such asa metal (e.g., brass, steel, aluminum, etc.), but may be formed of othermaterials (e.g., polymeric materials) dependent on the application inwhich valve assembly 10 is intended to be used.

As best shown in FIGS. 3-6 , valve apparatus 10 includes a valveassembly 24 that is located within cavity 22. Valve assembly 24 includesa valve retainer body 26, a poppet 28, and an adjustable valve seat 30.Valve retainer body 26 is preferably formed of a rigid material such asa metal or polymeric material, and is a generally cylindrical hollowstructure including a first end 32 that is closed and configured to belocated proximate an end wall 34 of cavity 22, and an opposite secondend 36 that is open and configured to be located proximate opening 20 ofcavity 22. First end 32 includes a first radially inwardly extendingrecess 38 that is configured for receipt of a first valve retainer bodyO-ring 40. Second end 36 includes a second radially inwardly extendingrecess 42 that is configured for receipt of a second valve retainer bodyO-ring 44. A third radially inwardly extending recess 46 is locatedbetween the first and second radially inwardly extending recesses 38 and42, which is configured for receipt of a third valve retainer bodyO-ring 48. Each of the valve retainer body O-rings 40, 44, and 48 areconfigured to provide a fluid-tight seal between valve retainer body 26and an interior surface 50 of cavity 22.

Valve retainer body 26 includes a first pair of apertures 52 or fluidports that are located between first radially inwardly extending recess38 and third radially inwardly extending recess 46. A second pair ofapertures 54 or fluid ports are located between second radially inwardlyextending recess 42 and third radially inwardly extending recess 46.First apertures 52 are configured to be aligned with inlet port 16,while second apertures 54 are configured to be aligned with outlet port18. While first and second apertures 52 and 54 are illustrated as beingslot-shaped, it should be understood that first and second apertures 52,54 can have any shape desired by one skilled in the art.

Poppet 28 is configured to be received within the hollow structure ofvalve retainer body 26, and is movable along an axis X of valve assembly24. Poppet 28 is preferably formed of a rigid material such as a metalor polymeric material, and includes a proximate end 56 that isconfigured to be located proximate first end 32 of valve retainer body26, and an opposite distal end 58 that is configured to be locatedproximate second end 36 of valve retainer body 26. A valve member 60 ispositioned between proximate end 56 and distal end 58. Valve member 60is configured to abut a valve seat 62 that is part of valve retainerbody 26, when valve assembly 24 is in the closed position. When valveassembly 24 is actuated, as will be described in more detail later,valve member 60 will be moved away from valve seat 62, which in turnwill permit fluid to flow from inlet 16 through first apertures 52, pastvalve member 60 toward the distal end 58 of poppet 28, and throughsecond apertures 54 into outlet 18. Alternatively, if outlet port 18functions as an inlet, the flow direction could be configured so thatfluid will flow from outlet port 18, through second apertures 54 pastvalve member 60, through first apertures 52, and out of inlet port 16.

Poppet 28 additionally includes a first seal member 64 attached to afirst depression 66 formed at proximate end 56, and a second seal member68 attached to a second depression 70 formed at distal end 58. First andsecond seal members 64 and 68 are similar to first, second, and thirdO-rings 40, 44, and 48, but are sized to correspond to poppet 28. Firstseal member 64 is configured to sealingly engage with an interiorsurface 72 of valve retainer member 26 at first end 32. Second sealmember 68 is configured to sealingly engage with an interior surface 74of adjustable valve seat 30.

Still referring to FIGS. 3-6 , adjustable valve seat 30 is a cylindricalmember that is configured to receive distal end 58 of poppet 28.Adjustable valve seat 30 includes an exterior threaded surface 76 thatis configured to mate with an interior threaded surface 78 formed at theinterior surface of valve retainer member 26 at second end 36 thereof.The adjustable valve seat 30 is described as being “adjustable” to anextent that, as best shown in FIG. 5 , a terminal end 80 of theadjustable valve seat 30 can overlap with second apertures 54 formed invalve retainer body 26, which may restrict flow through the secondapertures 54 when valve member 60 contacts terminal end 80. To increaseor decrease the flow through second apertures 54 formed in valveretainer body 26, the amount of threaded engagement between exteriorthreaded surface 76 of the adjustable valve seat 30 and the interiorthreaded surface 78 of valve retainer body 26 can be adjusted (i.e.,reduced or increased) such that the terminal end 80 does not overlapsecond apertures 54. Adjustable valve seat 30 includes a groove 82formed therein that is configured for receipt of an adjustable seatO-ring 84 that sealingly engages with interior surface 72 a of valveretainer body 26.

Valve apparatus 10 includes a solenoid assembly 86 that is configured toactuate valve assembly 24. Solenoid assembly 86 includes an adapterbushing 88 that is configured to connect solenoid assembly 86 to valveassembly 24. In this regard, adapter bushing 88 includes a hollowcylindrical body 90 having a first section 92 having a lesser diameterthan a second section 94. As best shown in FIG. 5 , first section 92includes an interior thread 96 that is configured to mate with an outerthread 98 formed on valve retainer body 26. In addition, first section92 includes an outer surface 100 that is configured to mate with opening20 of cavity block 12.

An armature 102 is positioned within solenoid assembly 86. Armature 102is a solid member formed of a material that can be magneticallyattracted, and includes a mating end 104 that is configured to mate withan internally threaded end 106 of poppet 28. Mating end 104 includes athreaded projection 108 connected to a main body 110 of armature 102 bya radially narrowed neck 112. Internally threaded end 106 of poppet 28is configured for receipt of the threaded projection 108. Radiallynarrowed neck 112 is connected to main body 110 of armature 102 via aradially expanded shoulder 116 that has a diameter that is greater thaneach of threaded projection 108, neck 112, and main body 110. Main body110 has a diameter than is greater than threaded projection 108 and neck112. Armature 102 is movable such that when a voltage or current isapplied to solenoid assembly 86, armature 102 can move poppet 28 betweenthe open and closed positions.

A hollow lower bushing 118 guides main body 110 of armature 102 withinadapter bushing 88. Lower bushing 118 includes an inner surface 120 thatextends along an outer surface 122 of main body 110 of armature 102.Lower bushing 118 includes a primary body 124 and a tubular sleeve 126.Primary body 124 includes a threaded surface 128 that is configured tomate with a threaded surface 130 of a solenoid housing 132 that houses asolenoid coil 134. An end face 136 of primary body 124 that facesradially expanded shoulder 116 includes a stepped annular recess 138that is configured for clearance of a plate spring 140 that ispositioned between shoulder 116 and annular recess 138. Recess 138 isstepped such that a first annular surface 142 of recess 138 is locatedcloser to shoulder 116 in comparison to a second annular surface 144 ofrecess 138. Plate spring 140 is mounted to first annular surface 142,and because second annular surface 144 is located further away fromshoulder 116, plate spring 140 is permitted to flex as armature 102 ismoved towards and away from valve assembly 24.

Plate spring 140, as best shown in FIG. 4 , includes an annular body 146having a central aperture 148 configured for receipt of main body 110 ofarmature 102. A plurality of secondary apertures 150 are locatedradially outward from central aperture 148. Secondary apertures 150 maybe round or oval-shaped, but any shape for secondary apertures 150 maybe selected that permits plate spring 140 to flex as armature 102 ismoved. Plate spring 140 may be formed of a rigid yet flexible material.Example materials include metal materials and polymeric materials. Platespring 140 is designed to valve assembly 24 to the closed position.

Solenoid housing 132, as noted above, houses a solenoid coil 134. Coil134 is mounted to a hollow cylindrical support structure 152. As bestshown in 4 and 6, coil 134 includes a pair of electrical leads 154 thatpermit a current or voltage to be applied to coil 134. An upper bushing156 including a pole piece 158 that is formed of a magnetizable materialis located within hollow support structure 152.

Upper bushing 156 is a sleeve-like structure including a cylindricalsleeve 160 that extends along pole piece 158, and a radially outwardlyextending flange 162 that is configured to be located between supportstructure 152 and a radially inwardly extending wall 164 of housing 132.Pole piece 158 includes a threaded surface 158 that mates with athreaded surface 160 formed in wall 164 of housing 132 to fix pole piece158 and upper bushing 158 to housing 132. While pole piece 158 isillustrated as having a central axially extending aperture 166, polepiece 158 is not required to have this feature. A cover piece 168 isattached to housing 132. Cover piece 168 is designed as a plug thatpermits a current or voltage application device (not shown) to becoupled to the electrical leads 154 of coil 134.

Upon application of a current or voltage to coil 134, pole piece 158 ismagnetized such that pole piece 158 can magnetically attract armature102. As armature 102 is pulled toward pole piece 158, armature 102 willpull poppet 28 toward pole piece 158 and plate spring 140 will be flexedbetween radially expanded shoulder 116 and lower bushing 118. As poppet28 is pulled toward pole piece 158, valve member 60 will be disengagedfrom valve seat 62 of valve retainer body 26 to open valve assembly 24,which permits fluid to travel from inlet 16 through first apertures 52,past valve member 60 toward the distal end 58 of poppet 28, and throughsecond apertures 54 into outlet 18. To close the valve assembly 24,application of the current or voltage to coil 134 is stopped at whichtime plate spring 140 can bias armature 102 and poppet 28 in a directionaway from pole piece 158. Valve member 60 of poppet 28 then reengageswith valve seat 62 to close the valve assembly 24. The same operationoccurs even if the function of valve inlet 16 and valve outlet 18 isreversed.

It should be understood that the combination of the position of theadjustable valve seat 30, a magnitude of the current or voltage appliedto coil 134, and the spring force exerted by plate spring 140 providesincreased control over the amount of fluid that may be permitted to passthrough valve assembly 24. In other words, the combination of theposition of the adjustable valve seat 30, the magnitude of the currentor voltage applied to coil 134, and the spring force exerted by platespring 140 controls the distance that valve member 60 can be movedrelative to valve seat 62 to increase and decrease the amount of fluidthat can pass through valve assembly 24.

In this regard, as noted above, the position of the adjustable valveseat 30 can be adjusted by adjusting the amount of threaded engagementbetween exterior threaded surface 76 of the adjustable valve seat 30 andthe interior threaded surface 78 of valve retainer body 26. In addition,the spring force of plate spring 140 can be determined prior to beingplaced in valve apparatus 10 to control the amount of bias at which theplate spring 140 biases valve member 60 of poppet into engagement withvalve seat 62. Once the spring force of plate spring 140 is determined,valve apparatus 10 can undergo testing to determine the amount ofmovement of armature 102 that occurs upon application of differentcurrents or voltages to coil 134. In this manner, the proportionalamount of fluid flow through valve assembly 24 at different currents orvoltages can be determined prior to being used in a system (not shown)in which valve apparatus is being used. In addition, it should beunderstood that the spring force of plate spring 140 can be adjusted bymodifying the size and/or number of secondary apertures 150, byadjusting a thickness of plate spring 140, or through selection of amaterial that forms plate spring 140.

Regardless of the manner in which the spring force of the plate spring140 is determined, it should be understood that increased proportionalcontrol over the distance that valve member 60 is moved relative tovalve seat 62 can be improved through the combination of the selectionof the plate spring 140 and the voltage or current that is applied tocoil 134. The data associated with the current or voltage that isapplied to coil 134 may be stored in a memory (not shown) of acontroller (not shown) that is attached to the current or voltageapplication device (not shown).

It should also be understood that the valve apparatus 10 is a balanceddesign where any fluctuations in the fluid supply pressure will notaffect the performance characteristics of the valve apparatus 10. Inthis regard, it should be understood that when the valve apparatus 10 isin the closed position (i.e., when valve member 60 of poppet 28 is incontact with valve seat 62 of valve retainer 26), the fluid forceexerted at inlet 16 is balanced (i.e., opposed) by the force exerted byseal 64 of poppet 28 against interior surface 72 of valve retainer 26.Similarly, when the valve apparatus 10 is in the fully open position(i.e., when valve member 60 of poppet 28 is in contact with terminal end80 of adjustable valve seat 30), the fluid force exerted at outlet 18 isbalanced (i.e., opposed) by the force exerted by seal 64 of poppet 28against interior surface 72 of valve retainer 26. When valve apparatus10 is at an intermediate open position (i.e., when valve member 60 ofpoppet 28 is disengaged from valve seat 62, but not in contact withterminal end 80 of adjustable valve seat 30), the fluid forces exertedat both inlet 16 and outlet 18 are balanced (opposed) by the forceexerted by seal 64 against interior surface 72 of valve retainer, theforce exerted by seal 68 against interior surface 74 of adjustable valveseat 30, and the force exerted by seal 84 against surface 72 a of valveretainer 26. Thus, even if the fluid forces exerted at inlet 16 andoutlet 18 fluctuate, the fluid forces at inlet 16 and outlet 18 arebalanced by the forces exerted by seals 64, 68, and 84, which enablesvalve assembly 24 to provide consistent performance (e.g., fluid outputat the correct pressure and amount) throughout the operational pressurerange of the valve apparatus 10.

Now referring to FIGS. 7-12 , a proportional solenoid valve apparatus200 according to a second aspect of the present disclosure will now bedescribed. Valve apparatus 200 is similar to valve apparatus 10described above. Accordingly, features of the valve apparatus 200 thatare common to those of the valve apparatus 10 will have the samereference numbers, and description of the common features will beomitted.

Valve apparatus 200 includes a housing or ported cavity block 202.Cavity block 202 is substantially similar to cavity block 12, butincludes a second opening 204 that communicates with opening 20 suchthat cavity 22 extends completely through cavity block 202. A valveassembly 206 is positioned within cavity 22 of cavity block 202. Valveassembly 206 includes valve retainer body 26, poppet 28, adjustablevalve seat 30, and valve retainer body O-rings 40, 44, and 48. Theprimary difference between valve assembly 206 and valve assembly 24 isthat valve assembly 206 additionally includes an end screw 208, a lowerdiaphragm 210, a lower end cap 212, an upper diaphragm 214, and an upperend cap 216. The use of the diaphragms 210, 214 and end caps 212, 216provide increased sealing of valve assembly 206—especially for liquidand low leakage applications.

Lower and upper diaphragms 210 and 214 are similar annular plates 218that include an edge portion 220, a central portion 222 that defines acentral aperture 224, and an annular bead 226 that extends between thecentral portion 222 and the edge portion 220. Edge portion 220, in adirection toward central portion 222, transitions into a first annularinclined surface 228 that terminates at bead 226. A second annularinclined surface 230 extends from bead 226 to central portion 222. Theuse of bead 226 and first and second inclined surfaces 228 and 230permits diaphragms 210 and 214 to slightly flex during use of valveassembly 206 to assist in sealing valve assembly 206. In this regard,the use of diaphragms 210, 214, end caps 212, 216, end screw 208, andarmature 102 remove the need for sealing members between poppet 28 andvalve retainer 26 that prevent valve assembly 206 from leaking.

In addition, by removing the need for sealing members between the poppet28 and valve retainer 26, poppet 28 is more easily controllable whenactuated by solenoid assembly 86 such that additional proportionalcontrol of the valve 200 is achieved. In this regard, no additionalforce is required to overcome the friction between poppet 28 and valveretainer 26 as is required when there are seal members 64 and 68 betweenpoppet 28 and valve retainer 26. Diaphragms 210 and 214 may be formed ofa rigid yet flexible material such as an elastomeric material or apolymeric material.

The edge portion 220 of lower diaphragm 210 is sandwiched between lowerend cap 212 and valve retainer member 26. In this regard, lower end cap212 includes a first cylindrical section 232 having an interior threadedsurface 234 that mates with a threaded surface 236 formed on valveretainer member 26. A second cylindrical section 238 having a diameterthat is less than the first cylindrical section 232 is connected tofirst cylindrical section 232 by a radially inwardly extending abutmentsurface 240. The abutment surface 240 faces first end 32 of valveretainer member 26, which in contrast to the first aspect of the presentdisclosure is open rather than closed. The edge portion 220 issandwiched between the abutment surface 240 and the open first end 32 ofthe valve retainer member 26.

Central portion 222 of lower diaphragm 210 is sandwiched betweenproximate end 56 of poppet 28 and end screw 208. End screw 208 includesa threaded shank 242 that extends through central aperture 224 and mateswith a threaded aperture 244 formed in proximate end 56 of poppet 28. Ahead 246 of threaded screw 208 extends radially outward from shank 242that extends along central portion 222 to second annular inclinedsurface 230. Head 246 includes a recess 248 that is configured forreceipt of a tool (not shown) that can rotate end screw 208 to mate withthreaded aperture 244 of poppet 28.

The edge portion 220 of upper diaphragm 214 is sandwiched between upperend cap 216 and valve retainer member 26. In this regard, upper end cap216 includes a first cylindrical section 250 having an interior threadedsurface 252 that mates with a threaded surface 254 formed on valveretainer member 26. A second cylindrical section 256 having a diameterthat is less than the first cylindrical section 250 is connected tofirst cylindrical section 250 by a radially inwardly extending abutmentsurface 258. The abutment surface 258 faces second end 36 of valveretainer member 26. The edge portion 220 is sandwiched between theabutment surface 258 and the second end 36 of the valve retainer member26. In this configuration, it is important to note that bead 226 oflower diaphragm 210 extends in a direction that is opposite to thedirection in which bead 226 of upper diaphragm 214 extends.

Central portion 222 of upper diaphragm 214 is sandwiched between distalend 58 of poppet 28 and radially expanded shoulder 116 of armature 102.Armature 102 includes a threaded shank 260 that extends through centralaperture 224 and mates with a threaded aperture 262 formed in proximateend 56 of poppet 28. Radially expanded shoulder 116 of armature 102extends radially outward from shank 260 and extends along centralportion 222 to second annular inclined surface 230.

Upper end cap 216 additionally includes an exterior threading 264 thatmates with the interior thread 96 of adapter bushing 88. With theexception of interior thread 96 of adapter bushing 88 coupling toexterior threading 264 of upper end cap 216, adapter bushing 88 is thesame as that described relative to the valve apparatus 10. In addition,valve apparatus 200 includes a solenoid assembly 86 that includes thesame features as that of valve apparatus 10. That is, the solenoidassembly 86 of valve apparatus 200 includes lower bushing 118, platespring 140, solenoid housing 132, coil 134, leads 154, upper bushing156, pole piece 158, and cover piece 168.

Upon application of a current or voltage to coil 134, pole piece 158 ismagnetized such that pole piece 158 can magnetically attract armature102. As armature 102 is pulled toward pole piece 158, armature 102 willpull poppet 28 toward pole piece 158 and plate spring 140 will becompressed between radially expanded shoulder 116 and lower bushing 118.As poppet 28 is pulled toward pole piece 158, valve member 60 will bedisengaged from valve seat 62 of valve retainer body 26 to open valveassembly 206, which permits fluid to travel from inlet 16 through firstapertures 52, past valve member 60 toward the distal end 58 of poppet28, and through second apertures 54 into outlet 18. To close the valveassembly 206, application of the current or voltage to coil 134 isstopped at which time plate spring 140 can bias armature 102 and poppet28 in a direction away from pole piece 158. Valve member 60 of poppet 28then reengages with valve seat 62 to close the valve assembly 206. Evenif the functions of inlet 16 and outlet 18 are reversed, valve assembly206 may operate in the same manner.

Similar to valve apparatus 10, it should be understood that thecombination of the position of the adjustable valve seat 30, a magnitudeof the current or voltage applied to coil 134, and the spring forceexerted by plate spring 140 provides increased control over the amountof fluid that may be permitted to pass through valve assembly 206. Inother words, the combination of the position of the adjustable valveseat 30, the magnitude of the current or voltage applied to coil 134,and the spring force exerted by plate spring 140 controls the distancethat valve member 60 can be moved relative to valve seat 62 to increaseand decrease the amount of fluid that can pass through valve assembly206.

In addition, because valve assembly 206 additionally includes diaphragms210, 214, end caps 212, 216, and end screw 208, the need for sealingmembers between poppet 28 and valve retainer 26 is removed. Moreover, byremoving the need for sealing members between the poppet 28 and valveretainer 26, poppet 28 is more easily controllable when actuated bysolenoid assembly 86 such that additional proportional control of thevalve 200 is achieved. In this regard, no additional force is requiredto overcome the friction between poppet 28 and valve retainer 26 as isrequired when there are seal members between poppet 28 and valveretainer 26.

It should also be understood that, similar to valve apparatus 10, thevalve apparatus 200 is a balanced design where any fluctuations in fluidpressure will not affect the performance characteristics of the valveapparatus 200. In this regard, while valve apparatus 200 does notinclude seals 64, 68, and 84, the balanced design is afforded bydiaphragms 210 and 214. More specifically, when valve assembly 206 is inthe open or closed position, it should be understood that fluid frominlet 16 can be located between annular bead 226 of lower diaphragm 210and poppet 28. Due to annular bead 226 formed by inclined surfaces 228and 230, a force is exerted by lower diaphragm 210 in a directionorthogonal to inlet 16 and outlet 18 (i.e., along axis X) that balancesthe fluid force exerted at inlet 16 or outlet 18 when the valve assembly206 is in the open or closed positions, respectively. When valveassembly 206 is in an intermediate open position (i.e., when valvemember 60 of poppet 28 is not engaged with either valve seat 62 of valveretainer 26 or engaged with adjustable valve seat 30), the fluid forcesexerted at inlet 16 and outlet 18 are balanced (i.e., opposed) by forcesexerted on the fluid by each of the annular beads 216 of both diaphragms210 and 214. Thus, even if the fluid forces exerted at inlet 16 andoutlet 18 fluctuate, the fluid forces at inlet 16 and outlet 18 arebalanced by the forces exerted by diaphragms 210 and 214, which enablesconsistent performance throughout the operational pressure range of thevalve apparatus 200.

Lastly, it should be understood each of the valve apparatuses 10 and 200described above are capable of being modified to have different flowcapabilities over a wider range of fluid pressures, without having tochange the overall structure thereof. More specifically, if a flow ratein a particular application is to be changed, previous valve apparatusdesigns would require a structural redesign to the valve apparatus inthe form of, for example, changing an orifice size, adding a spring tobalance different flow pressures, or increasing and/or decreasing thesize of various components of the valve apparatus. The valve apparatuses10 and 200 of the present disclosure, however, only require minormodifications to, for example, the position of the adjustable valve seat30 or the position of the pole piece 158 to adjust the flow capabilityof the valve apparatus.

In this regard, as noted above, pole piece 158 is threadingly engagedwith housing 132. The position of pole piece 158, therefore, can beadjusted by adjusting the amount of threaded engagement with housing132, which can permit the poppet 28 to move a greater or lesser distancewhen actuated by solenoid assembly 86. Thus, by adjusting pole piece 158in combination with adjusting the position of adjustable valve seat 30,valve apparatuses 10 and 200 do not need to be structurally redesignedin order to accommodate different flow outputs over a wider range ofpressures.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

What is claimed is:
 1. A valve comprising: a valve assembly that isconfigured to selectively permit communication between a fluid inlet anda fluid outlet, the valve assembly including a hollow valve retainerhaving a first port that is configured to communicate with a fluidinlet, a second port that is configured to communicate with a fluidoutlet, and a valve seat between the first port and the second port, thehollow valve retainer housing a movable poppet including a valve memberthat is configured is engage and disengage with the valve seat to permitfluid to travel from the fluid inlet through the first port to thesecond port, and then to the fluid outlet; a solenoid assembly coupledto the valve assembly that is configured to actuate the valve assemblyto permit the communication between the fluid inlet and the fluidoutlet, the solenoid assembly including an armature integral with thepoppet, a first bushing that surrounds the armature, a plate springpositioned between the armature and the first bushing, and a solenoidcoil that is configured to move the armature and the poppet to permitthe communication between the fluid inlet and the fluid outlet, whereinthe plate spring is configured to bias the valve member of the poppetinto engagement with the valve seat of the valve retainer, the platespring having a spring force, the solenoid coil is configured to movethe armature and the poppet based a voltage or current that is appliedto the solenoid coil, and based on the spring force of the plate springand the voltage or current that is applied to the solenoid coil, thesolenoid assembly is configured to control a distance that the valvemember moves relative to the valve seat of the valve retainer toproportionally control an amount of flow that is permitted through thevalve assembly.
 2. The valve according to claim 1, wherein the valveassembly further comprises an adjustable valve seat that is coupled tothe valve retainer, is positioned about the poppet, and includes aterminal end that is engageable with the valve member when the valvemember is moved away from the valve seat of the valve retainer.
 3. Thevalve according to claim 2, wherein the adjustable valve seat isthreadingly coupled to the valve retainer, a position of the adjustablevalve seat being variable by adjusting an amount of threading engagementbetween the adjustable valve seat and the valve retainer.
 4. The valveaccording to claim 3, wherein the solenoid assembly includes a polepiece having a position in the solenoid assembly that is adjustable, andin combination with adjusting the position of the adjustable valve seat,the valve assembly is configured to provide different flow capabilitiesbetween the fluid inlet and the fluid outlet.
 5. The valve according toclaim 1, wherein the solenoid assembly further comprises a secondbushing that houses a pole piece that is located proximate the armature,and that is configured to be magnetized by the coil to attract thearmature to open the valve assembly.
 6. The valve according to claim 1,wherein the plate spring includes an annular body having a centralaperture configured for receipt of the armature, and a plurality ofsecondary apertures that are located radially outward from the centralaperture.
 7. The valve according to claim 1, wherein the first bushingincludes a stepped recess that is configured for receipt of the platespring, the stepped recess including a first annular surface and asecond annular surface located radially inward from the first annularsurface, and the plate spring being mounted to the first annularsurface.
 8. The valve according to claim 1, further comprising anadapter that is configured to connect the solenoid assembly to the valveassembly.
 9. The valve according to claim 1, wherein the valve assemblyfurther comprises a first diaphragm located proximate a first end of thevalve retainer, and a second diaphragm located proximate an opposingsecond end of the valve retainer and the armature, the first and seconddiaphragms being configured to balance fluid pressures exerted at thefluid inlet and the fluid outlet to prevent fluctuations in the fluidpressures exerted at the fluid inlet and fluid outlet from affectingperformance of the valve assembly.
 10. The valve according to claim 9,wherein each of the first and second diaphragms are formed of an annularplate that includes an annular bead that surrounds a central aperture ofthe annular pate, the bead being defined by a first annular inclinedsurface and second annular inclined surface.
 11. The valve according toclaim 9, wherein the valve assembly further comprises a first end capmated to a first end of the valve retainer and a second end cap mated toan opposite second end of the valve retainer, wherein the firstdiaphragm is sandwiched between the first end cap and the first end ofthe valve retainer, and the second diaphragm is sandwiched between thesecond end cap and the second end of the valve retainer.
 12. The valveaccording to claim 1, further comprising a plurality of seal membersbetween the poppet and the valve retainer, the plurality of seal membersconfigured to balance fluid pressures exerted at the fluid inlet and thefluid outlet to prevent fluctuations in the fluid pressures exerted atthe fluid inlet and fluid outlet from affecting performance of the valveassembly.
 13. A valve comprising: a valve assembly that is configured toselectively permit communication between a fluid inlet and a fluidoutlet, the valve assembly including: a hollow valve retainer having afirst port that is configured to communicate with the fluid inlet, asecond port that is configured to communicate with the fluid outlet, anda valve seat between the first port and the second port; a movablepoppet located within the valve retainer, the poppet including a valvemember that is configured is engage and disengage with the valve seat topermit fluid to travel from the fluid inlet through the first port tothe second port, and then to the fluid outlet; a first diaphragm locatedproximate a first end of the valve retainer; and a second diaphragmlocated proximate an opposing second end of the valve retainer; and asolenoid assembly coupled to the valve assembly that is configured toactuate the valve assembly to permit the communication between the fluidinlet and the fluid outlet, the solenoid assembly including a movablearmature engaged with the poppet, a first bushing that surrounds thearmature, a plate spring positioned between the armature and the firstbushing, and a solenoid coil that is configured to move the armature andthe poppet to permit the communication between the fluid inlet and thefluid outlet, wherein the plate spring is configured to bias the valvemember of the poppet into engagement with the valve seat of the valveretainer, the plate spring having a spring force, the solenoid coil isconfigured to move the armature and the poppet based a voltage orcurrent that is applied to the solenoid coil, and based on the springforce of the plate spring and the voltage or current that is applied tothe solenoid coil, the solenoid assembly is configured to control adistance that the valve member moves relative to the valve seat of thevalve retainer to proportionally control an amount of flow that ispermitted through the valve assembly.
 14. The valve according to claim13, further comprising an adjustable valve seat that is coupled to thevalve retainer, is positioned about the poppet, and includes a terminalend that is engageable with the valve member when the valve member ismoved away from the valve seat of the valve retainer, wherein theadjustable valve seat is threadingly coupled to the valve retainer, aposition of the adjustable valve seat being variable by adjusting anamount of threading engagement between the adjustable valve seat and thevalve retainer.
 15. The valve according to claim 14, wherein thesolenoid assembly includes a pole piece having a position in thesolenoid assembly that is adjustable, and in combination with adjustingthe position of the adjustable valve seat, the valve assembly isconfigured to provide different flow capabilities between the fluidinlet and the fluid outlet.
 16. The valve according to claim 13, whereinthe solenoid assembly further comprises a second bushing that houses apole piece that is located proximate the armature, and that isconfigured to be magnetized by the coil to attract the armature to openthe valve assembly.
 17. The valve according to claim 13, wherein theplate spring includes an annular body having a central apertureconfigured for receipt of the armature, and a plurality of secondaryapertures that are located radially outward from the central aperture.18. The valve according to claim 13, wherein the first bushing includesa stepped recess that is configured for receipt of the plate spring, thestepped recess including a first annular surface and a second annularsurface located radially inward from the first annular surface, and theplate spring being mounted to the first annular surface.
 19. The valveaccording to claim 13, further comprising an adapter that is configuredto connect the solenoid assembly to the valve assembly.
 20. The valveaccording to claim 13, wherein each of the first and second diaphragmsare formed of an annular plate that includes an annular bead thatsurrounds a central aperture of the annular pate, the bead being definedby a first annular inclined surface and second annular inclined surface.21. The valve according to claim 13, wherein the first and seconddiaphragms are configured to balance fluid pressures exerted at thefluid inlet and the fluid outlet to prevent fluctuations in the fluidpressures exerted at the fluid inlet and fluid outlet from affectingperformance of the valve assembly.